U.S. patent application number 17/842212 was filed with the patent office on 2022-09-29 for systems and methods for cell culturing.
The applicant listed for this patent is FLASKWORKS, LLC. Invention is credited to Andrew Kozbial, Shashi K. Murthy.
Application Number | 20220306977 17/842212 |
Document ID | / |
Family ID | 1000006406059 |
Filed Date | 2022-09-29 |
United States Patent
Application |
20220306977 |
Kind Code |
A1 |
Murthy; Shashi K. ; et
al. |
September 29, 2022 |
SYSTEMS AND METHODS FOR CELL CULTURING
Abstract
Cell culture systems and methods provide improved
immunotherapeutic product manufacturing with greater scalability,
flexibility, and automation. Cell culture systems are configured
with interchangeable cartridges, allowing versatility and
scalability. Systems are configured to have multiple connected cell
culture chambers, which allows parallel processing of different
types of cells. Gas-impermeable cell culture chambers and methods
for generating cells in closed systems prevent contamination and
user error. Methods for recycling cell culture medium provide
additional efficiencies.
Inventors: |
Murthy; Shashi K.; (Newton,
MA) ; Kozbial; Andrew; (East Boston, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FLASKWORKS, LLC |
Boston |
MA |
US |
|
|
Family ID: |
1000006406059 |
Appl. No.: |
17/842212 |
Filed: |
June 16, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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17074921 |
Oct 20, 2020 |
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17842212 |
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62923963 |
Oct 21, 2019 |
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62923967 |
Oct 21, 2019 |
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62923973 |
Oct 21, 2019 |
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62923975 |
Oct 21, 2019 |
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62923978 |
Oct 21, 2019 |
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62923982 |
Oct 21, 2019 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C12M 35/08 20130101;
C12M 45/22 20130101; C12N 5/0638 20130101; C12M 29/14 20130101;
C12N 2501/998 20130101; A01N 1/0221 20130101; C12M 23/48 20130101;
C12M 33/12 20130101; A61K 35/17 20130101; C12M 41/34 20130101; C12M
37/04 20130101; C12N 5/0636 20130101; C12M 23/58 20130101; C12N
2502/1157 20130101; C12M 23/24 20130101; C12N 5/0639 20130101; C12M
41/14 20130101; C12M 29/10 20130101; C12N 5/0637 20130101; C12M
29/00 20130101; C12N 2502/1121 20130101; C12N 5/00 20130101; C12M
41/48 20130101 |
International
Class: |
C12M 1/00 20060101
C12M001/00; C12M 1/04 20060101 C12M001/04; C12M 1/42 20060101
C12M001/42; C12M 1/36 20060101 C12M001/36; C12N 5/0784 20060101
C12N005/0784; C12M 1/26 20060101 C12M001/26; A01N 1/02 20060101
A01N001/02; C12N 5/0783 20060101 C12N005/0783; C12M 1/12 20060101
C12M001/12; C12M 1/34 20060101 C12M001/34; C12N 5/00 20060101
C12N005/00; C12M 3/00 20060101 C12M003/00 |
Claims
1.-13. (canceled)
14. A method for producing neoantigen-targeting T cells, the method
comprising: producing mature dendritic cells presenting one or more
tumor-specific peptides in a first cell culture chamber; flowing
purified T cells from a second culture chamber into the first cell
culture chamber; and co-culturing the purified T cells with the
mature dendritic cells to thereby produce expanded
neoantigen-targeting T cells in the first cell culture chamber.
15. The method of claim 14, wherein the one or more tumor-specific
peptides are selected from a library of a plurality of
tumor-specific peptides.
16. The method of claim 14, wherein the co-culturing step completes
a first stimulation cycle.
17. The method of claim 14, further comprising: generating a second
batch of mature dendritic cells in a cell culture chamber; and
introducing the expanded T cells from the first culture chamber
into the cell culture chamber containing the second batch of mature
dendritic cells to co-culture the expanded T cells with the second
batch of mature dendritic cells to complete a second stimulation
cycle.
18. The method of claim 17, wherein the second batch of mature
dendritic cells have been stimulated with a different set of
peptides than the mature dendritic cells from the first culture
chamber.
19. The method of claim 17, further comprising: transferring the
expanded T cells that have been co-cultured with the second batch
of mature dendritic cells to a cell culture chamber comprising a
third batch of mature dendritic cells to complete a third
stimulation cycle.
20. The method of claim 19, wherein the third batch of mature
dendritic cells have been stimulated with a different set of
peptides than the mature dendritic cells from the second batch.
21. The method of claim 19, wherein the stimulation cycle is
repeated from 4 to 25 times.
22. The method of claim 14, wherein the mature dendritic cells are
generated from monocytes from a patient.
23. The method of claim 22, wherein the monocytes are purified and
introduced into the first cell culture chamber.
24. The method of claim 22, wherein the monocytes are perfused with
cell culture medium and contacted with antigen material comprising
tumor-specific peptides.
25. The method of claim 14, wherein the dendritic cells and the T
cells are processed in parallel.
26. The method of claim 14, wherein the first and second culture
chambers are made of polystyrene.
27. The method of claim 14, wherein the first and second culture
chambers are connected via a sterile tube.
28. The method of claim 14, wherein the cell culture medium is
provided in sterile vessel and is connected to the closed system by
sterile tube welding.
29. The method of claim 14, wherein flowing the cell culture medium
into the first culture chamber comprises eliminating headspace in
the first culture chamber.
30. The method of claim 14, further comprising: draining fluid from
the first culture chamber; washing the neoantigen transduced T
cells with a buffer; and flowing a cryopreservation medium into the
first culture chamber to re-suspend the neoantigen transduced T
cells.
31. The method of claim 14, further comprising flowing the
neoantigen transduced T cells into a harvesting vessel in a closed
manner.
32. The method of claim 14, wherein each of the flowing steps is
done via sterile tubes.
33. The method of claim 32, wherein the sterile tubes are connected
by sterile tube welding.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to, and the benefit of,
U.S. Provisional Application No. 62/923,963, filed Oct. 21, 2019,
and to U.S. Provisional Application No. 62/923,967, filed Oct. 21,
2019, and to U.S. Provisional Application No. 62/923,973, filed
Oct. 21, 2019, and to U.S. Provisional Application No. 62/923,975,
filed Oct. 21, 2019, and to U.S. Provisional Application No.
62/923,978, filed Oct. 21, 2019, and to U.S. Provisional
Application No. 62/923,982, filed Oct. 21, 2019, the contents of
which are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The present disclosure relates generally to systems and
methods for cell culturing.
BACKGROUND
[0003] Cancer is a leading cause of mortality and morbidity
worldwide, and despite years of extraordinary research efforts,
treatments have remained elusive. The diversity of tumor types
presents a challenge in cancer therapy, as treatments tailored to
one tumor may not be effective against another. Personalized
treatments have been sought, but many challenges exist in
developing them.
[0004] One promising area has been T cell therapy, wherein a
patient's T cells are altered to target certain cancers. This
includes chimeric antigen receptor T cell (CAR-T) therapy, T cell
receptor (TCR) therapy, and neoantigen-based T cell therapy.
Neoantigen-based therapies provide the ability to identify antigens
from tumor sequencing data to design highly personalized
patient-specific immunotherapies.
[0005] Unfortunately, many challenges exist in the development and
manufacture of T cell therapies. Existing processes for isolation,
preparation, and expansion of cancer antigen-specific T-cells are
limited. Conventional protocols for stimulation of human T cells by
autologous antigen-presenting dendritic cells (DCs) involve several
manual steps, including transferring cells between culture vessels,
changing media, and replenishing cytokines and cell medium. Those
processes are labor-intensive and not readily scalable. The number
of manual steps required to carry out the protocol is prohibitively
high. Additionally, those protocols involve the use of flasks or
other containers, which are opened and closed during use, adding to
the risk of contamination which can compromise the quality and
safety of the cell product. Such methods do not comply with current
good manufacturing practices (cGMP) and are not useful for
producing T cell therapies at large scale. Additional challenges
also exist, such as time of cell preparation, maintenance of
optimal phenotype, expansion to sufficient cell number, and quality
and safety of the cell product.
SUMMARY
[0006] The invention recognizes that automating T cell therapy
processing and manufacturing has been unsuccessful due to the
complex biological processes associated as well as the bioprocess
and regulatory requirements associated with autologous cell
processing. The few systems that do exist are overly complex and
cost-prohibitive, and are therefore are not useful for pre-clinical
assays. The inventive cell culture systems and related methods of
the invention provide solutions to many of the problems in cell
culturing and provides numerous features to decrease contamination
and user error, as well as increase efficiency, scalability, and
ease of use. The systems and methods of the invention provide
capabilities for robust T cell production, while minimizing cost
and increasing simplicity and ease of use, making the disclosed
systems and methods useful for both pre-clinical research and
routine cell culture, while being capable of meeting requirements
for current good manufacturing practices for clinical
manufacturing.
[0007] In certain aspects, the disclosed systems and methods
provide improved automated technology for producing
antigen-specific T cells. Automation of the manual processes
dramatically reduces opportunities for user error and decreases the
risk of contamination. For example, the disclosure provides systems
and methods for producing CAR-T and TCR transduced T cells, as well
as neoantigen-targeting T cells in a closed system. This avoids the
need to open and close T flasks, as is common in the prior art,
thereby simplifying the process and avoiding sources of
contamination. As another example, cell culture systems are
disclosed which are configured with easily interchangeable cell
culture chambers, allowing the user to scale up or scale down a
cell population. The various chambers and vessels are connectable
via sterile tube welding, so that the system can remain closed
throughout use. The disclosure also provides gas-impermeable
cartridges for cell culture, which provide a solid polystyrene
surface for optimal cell adhesion and rigid cartridge construction
which is easy to manufacture and less susceptible to contamination
when operated with welded tube connections. The disclosed systems
also allow parallel processing of dendritic cells and T cells in a
process for generating stimulated T cells. The system architecture
streamlines the process of T cell culture, providing savings in
time and materials. Another way that the system saves materials is
by recycling cell culture medium, to ensure that cells can be
cultured with minimal amount of expensive culture medium and
supplements.
[0008] In addition to the features described above, other features
will be apparent to those of skill in the art, as the disclosed
systems and methods provide numerous opportunities for process
optimization in immunotherapeutic product manufacturing.
[0009] Aspects of the disclosure provide a cell culture system with
interchangeable cartridges. The cell culture system includes a
first area configured to receive a fluid reservoir containing a
cell culture medium and a second area configured to receive a waste
reservoir. The cell culture system also has one or more pumps
fluidically connectable to the fluid reservoir and a substrate
configured to receive and retain cell culture chambers of different
shapes and/or sizes.
[0010] In embodiments, the substrate has a plurality of different
openings arranged such that the substrate is configured to receive
and retain cell culture chambers of different shapes and/or sizes.
The substrate can be configured to receive and retain multiple cell
culture chambers simultaneously. A first portion of the substrate
may be configured to receive a first cell culture chamber of a
first size whereas a second portion of the substrate is configured
to receive a second cell culture chamber of a second shape which is
different from the first size. In embodiments, the first portion of
the substrate is configured to receive a first cell culture chamber
of a first shape and the second portion of the substrate is
configured to receive a second cell culture chamber of a second
shape that is different from the first shape. In embodiments, the
first portion of the substrate is configured to receive a first
cell culture chamber of a first size and shape and a second portion
of the substrate is configured to receive a second cell culture
chamber of a second size and shape that is different from the first
size and shape.
[0011] In embodiments, the fluid reservoir is positioned in the
first area and the waste reservoir is positioned in the waste area.
One or more tubes can be included that fluidically connect the
fluid reservoir to the one or more pumps, and/or the one or more
pumps to the cell culture chambers, and/or the cell culture
chambers to the waste reservoir. Each cell culture chamber can be
fluidically coupled to a separate pump. In some embodiments, a
processor is operably connected to the one or more pumps and one or
more sensors are operable to measure a characteristic of a fluid in
the cell culture system, wherein the processor operates the one or
more pumps based on the measured characteristic.
[0012] In a related aspect, the disclosure provides a method for
culturing cells. The method includes providing a cell culture
system that has a first area configured to receive a fluid
reservoir containing a cell culture medium and a second area
configured to receive a waste reservoir, one or more pumps
fluidically connectable to the fluid reservoir, and a substrate
configured to receive and retain cell culture chambers of different
shapes and/or sizes. The method further involves loading the fluid
reservoir into the first area and the waste reservoir into the
second area, loading a first cell culture chamber of a first size
and/or shape onto a first portion of the substrate, and loading a
second cell culture chamber of a second size and/or shape onto a
second portion of the substrate. The method further involves
connecting the fluid reservoir, the one or more pumps, the first
and second cell culture chambers, and the waste reservoir with
tubing. The method further involves operating the system to culture
cells in the first and second cell culture chambers.
[0013] In embodiments, the substrate has a plurality of different
openings arranged such that the substrate is configured to receive
and retain cell culture chambers of different shapes and/or sizes.
The first cell culture chamber can be of a first size and the
second cell culture chamber can be of a second size. The first cell
culture chamber can be of a first shape and the second cell culture
chamber can be of a second shape. The first cell culture chamber
can be of both a first size and shape, and the second cell culture
chamber can be of both a second size and shape.
[0014] In embodiments, each of the first and second cell culture
chambers is fluidically coupled to a separate pump. The system can
also include a processor operably connected to the one or more
pumps and one or more sensors operable to measure a characteristic
of a fluid in the cell culture system, wherein the processor
operates the one or more pumps based on the measured
characteristic.
[0015] In embodiments, after cell culturing is complete in the
first and second cell culture chambers, the cultured cells in each
of the first and second cell culture chambers are collected. The
cultured cells in each of the first and second cell culture
chambers can be collected in the same collection vessel or in
different collection vessels.
[0016] In another aspect, the disclosure provides a method for
producing transduced T cells with CAR or TCR in a closed system.
The method involves providing a cell culture instrument that has
first and second culture chambers and flowing a suspension
containing cells into the first culture chamber. The method further
involves perfusing the T cells in the first culture chamber with
appropriate transduction and expansion reagents to produce
transduced T cells which expand in the first culture chamber. The
method further involves flowing the transduced and expanded T cells
from the first culture chamber into the second culture chamber. The
method further involves flowing a cell culture medium into the
second culture chamber to further expand the transduced and
expanded T cells, wherein the method is performed on a single
instrument in a closed manner such that sterility is maintained
throughout the method.
[0017] In some embodiments, the second culture chamber is larger
than the first culture chamber. One or both culture chambers can be
made of polystyrene. The culture chambers can be connected via a
sterile tube. The first culture chamber may have an activation
reagent and/or a cell transduction reagent, which may be an
inactive virus expressing CAR or TCR. Alternatively the second
culture chamber may be a separate cell culture instrument that is
not part of the first cell culture instrument.
[0018] In embodiments, the cell culture medium is provided in a
sterile vessel and is connected to the closed system by sterile
tube welding. Flowing the cell culture medium into the first
culture chamber may involve eliminating headspace in the first
culture chamber. The cell culture medium may include Aim V with
interleukin-2.
[0019] The method may further involve activating the T cells in the
first culture chamber, which can be done by contacting with a
magnetic or non-magnetic bead comprising one or more activating
antibodies or soluble activation antibody-containing reagents, and
a transduction reagent. The method may further involve draining
fluid from the second culture chamber, washing the transduced and
expanded T cells with a buffer, and flowing a cryopreservation
medium into the second culture chamber to re-suspend the transduced
and expanded T cells. the method may further involve flowing the
transduced and expanded T-cells into a harvesting vessel in a
closed manner.
[0020] In embodiments, each of the flowing steps may be done via
sterile tubes. The sterile tubes may be connected by sterile tube
welding.
[0021] In another aspect, the disclosure provides a method for
producing neoantigen-targeting T cells in a closed system. The
method includes providing a cell culture instrument having first
and second culture chambers and flowing cell culture medium
containing monocytes into the first culture chamber. The method
also involves perfusing the purified monocytes in the first culture
chamber to produce dendritic cells in the first culture chamber and
contacting the dendritic cells with antigen material, which may
include tumor-specific peptides, in the first culture chamber to
produce mature dendritic cells. The method further involves flowing
the mature dendritic cells from the first culture chamber into the
second culture chamber comprising purified T cells to co-culture
the mature dendritic cells and the purified T cells, to thereby
produce neoantigen-targeting T cells. The method is performed on a
single instrument in a closed manner such that sterility is
maintained throughout the method.
[0022] In embodiments, the method also involves flowing a second
batch of monocytes into the second culture chamber, differentiating
them into dendritic cells and maturing the dendritic cells, in
order to then perform a second co-culture with the purified T
cells. The first and second culture chambers can be made of
polystyrene. The first and second culture chambers can be connected
via a sterile tube. The cell culture medium can be provided in a
sterile vessel and can be connected to the closed system by sterile
tube welding. The step of flowing the cell culture medium into the
first culture chamber can involve eliminating headspace in the
first culture chamber. Each of the flowing steps can be done via
sterile tubes, which may be connected by sterile tube welding.
[0023] In embodiments, the method also includes activating the T
cells in the second culture chamber. In embodiments, the method
also includes draining fluid from the second culture chamber,
washing the neoantigen-targeting T cells with a buffer, and flowing
a cryopreservation medium into the second culture chamber to
re-suspend the neoantigen-targeting T cells. The method may also
involve flowing the neoantigen-targeting T cells into a harvesting
vessel in a closed manner.
[0024] In another aspect, the disclosure provides a method for
parallel processing to produce dendritic cells and stimulate T
cells in parallel. The method includes providing a cell culture
instrument with first and second culture chambers and flowing cell
culture medium containing monocytes into the first culture chamber.
The method further includes perfusing the monocytes in the first
culture chamber to produce dendritic cells in the first culture
chamber. The method further includes flowing T cells that have been
cultured in the second culture chamber from the second culture
chamber into the first culture chamber with the dendritic cells to
further culture the T cells in the first culture chamber. In
embodiments, sterility is maintained throughout the method.
[0025] The method may also include collecting the cultured T cells
from the first culture chamber by flowing the cultured T cells into
a collection vessel. The method may also include maturing the
dendritic cells in the first culture chamber by contacting the
dendritic cells with antigen material, which may include
tumor-specific peptides. In embodiments, the method also involves
activating the T cells in the second culture chamber, which can be
done by using an activation reagent. In embodiments, the method
also involves washing the stimulated T cells with a buffer, and
optionally transferring the stimulated T cells to a
cryopreservation medium. The method may also involve flowing the
neoantigen-targeting T cells into a harvesting vessel in a closed
manner. Each of the flowing steps can be done via sterile tubes,
which are optionally connected by sterile tube welding.
[0026] The cell culture medium may be provided in a sterile vessel
and may be connected to the closed system by sterile tube welding.
Flowing the cell culture medium into the first culture chamber may
involve eliminating headspace in the first culture chamber. In
embodiments, the first and second culture chambers are made of
polystyrene, and optionally may be connected via a sterile tube. In
some embodiments, one or both of the first and second cell culture
chambers from the cell culture instrument can be replaced and the
method can be repeated.
[0027] In another aspect, the disclosure provides a gas-impermeable
cell culture chamber, wherein a top, a bottom, and both side walls
are comprised of a gas-impermeable material. The gas-impermeable
material may also be a material to which cells adhere. The
gas-impermeable material may be polystyrene.
[0028] In embodiments, the cell culture chamber has an inlet. The
cell culture chamber may also have an outlet. The inlet and the
outlet can be located on the top of the cell culture chamber, and
optionally the inlet and the outlet are each configured to
fluidically and sealably couple with tubing. The cell culture
chamber can be integrally formed, and it can be sized and
configured to fit within an incubator. The cell culture chamber can
be sized and configured to couple to a substrate of a cell culture
instrument.
[0029] In a related aspect, the disclosure provides a method for
culturing cells that involves providing a cell culture chamber
having an inlet and an outlet, wherein a top, a bottom, and both
side walls are made of a gas-impermeable material. The method also
involves loading cells in to the cell culture chamber and flowing a
cell culture medium into the cell culture chamber via the inlet to
culture the cells in the culture chamber and out of the cell
culture chamber via the outlet, wherein the flowing of the cell
culture medium through the cell culture chamber via the inlet and
the outlet causes continuous flow of cell culture medium through
the cell culture chamber and allows for gas exchange to occur
between the cells in the cell culture chamber and the cell culture
medium.
[0030] In embodiments, the gas-impermeable material is also a
material to which cells adhere, such as polystyrene. In
embodiments, the inlet and the outlet are located on the top of the
cell culture chamber and are optionally configured to fluidically
and sealably couple with tubing. The tubing can be high
permeability tubing which allows the cell culture medium to
exchange gas while in the high permeability tubing. In embodiments,
the cell culture chamber is integrally formed. The cell culture
chamber can be sized and configured to fit within an incubator and
optionally it can be sized and configured to couple to a substrate
of a cell culture instrument.
[0031] In another aspect, the disclosure provides a method for
culturing cells that involves culturing cells in a cell culture
chamber on a cell culture instrument by flowing a cell culture
medium through the cell culture chamber, wherein a portion of the
cell culture medium that has already been flowed through the cell
culture chamber is recycled back into the cell culture chamber
during the cell culturing process.
[0032] In embodiments, the method also involves measuring one or
more parameters of the used medium prior to the recycling. The
parameters can be a concentration of one or more compounds within
the used medium, such as glucose, lactate, dissolved oxygen, or
cell metabolites. The parameter can also be pH or cell number.
[0033] In embodiments, the method involves determining, using a
processor operably connected to the cell culture chamber, whether
at least one of the one or more parameters of the used medium meets
a predetermined threshold prior to the recycling step. The
measuring step can be performed by one or more sensors operably
associated with the cell culture chamber. The one or more sensors
can be operably associated with a waste reservoir in fluid
communication with the cell culture chamber. The cell culture
chamber can be operably connected to one or more pumps, and may
have an inlet and an outlet. The recycling step may involve
redirecting the portion of used medium from the waste reservoir
back into the cell culture chamber. In embodiments, the portion of
used medium is combined with a bolus of fresh medium.
[0034] In a related aspect, the disclosure provides a method for
culturing cells, which involves providing a cell culture chamber
containing cells, flowing a cell culture medium into the cell
culture chamber, removing used cell culture medium from the cell
culture chamber, assessing a parameter of the used cell culture
medium, and returning the used cell culture medium to the cell
culture chamber if the parameter meets a predetermined
threshold.
[0035] In embodiments, the method also involves combining the used
cell culture medium with a bolus of fresh cell culture medium prior
to the returning step. The assessing step may involve measuring the
parameter using a sensor operably coupled to the cell culture
chamber. The assessing step may involve determining, using a
processor, whether the parameter meets the predetermined threshold.
The parameter may be a measured concentration of one or more
compounds within the used cell culture medium, such as glucose,
lactate, or cell metabolites. In embodiments, the returning step
comprises redirecting the used cell culture medium from a waste
reservoir into the cell culture chamber. In other embodiments, the
method also involves discarding the used cell culture medium if the
parameter does not meet the predetermined threshold, and flowing
fresh cell culture medium into the cell culture chamber.
[0036] In another aspect, this disclosure provides a cell culture
system that includes a plurality of shelves for receiving fluid
reservoirs. The shelves may be stacked with a first shelf on top of
a second shelf, each of the first and second shelves configured to
receive a fluid reservoir. Each of the shelves may include a
retaining mechanism that retains the fluid reservoir on each of the
first and second shelves.
[0037] The system may further include at least one pump, a
processor operably coupled to the at least one pump; and a
substrate sized and configured to hold a plurality of cell culture
chambers at a same time. Preferably, the system further includes at
least one sensor, and the processor may be connected to the at
least one sensor and can configured to operate the at least one
pump based on a characteristic measured by the sensor. For example,
the sensor may measure a concentration of one or more compounds
within cell culture medium, such as glucose, lactate, or cell
metabolites. The processor may regulate the pump (e.g., turn the
pump on or off) based on measurements made from one or more
sensors. For example, one sensor may be attached to a cell culture
chamber. That sensor may measure, for example, glucose levels
inside the media within the cell culture chamber. When the glucose
levels fall below a pre-determined threshold, the processor may
trigger the pump to replace the media in the cell culture
chamber.
[0038] In some embodiments, the processor is configured to receive
and execute instructions for culturing a cell type. In other
instances, the processor may be configured to receive and execute
instructions for transducing T cells.
[0039] In some embodiments, the substrate is configured to receive
cell culture chambers of different sizes and/or shapes. This
configuration is advantageous because it allows the system to be
customized to culture different quantities of cells, or different
cell types, depending on the particular needs of the user. The
system may further include a plurality of pumps. For example, the
system may include a separate pump for each cell culture chamber
included within the system allowing for cells within each cell
culture chamber to be separately cultured.
[0040] In some embodiments, the system further includes a plurality
of tubes that fluidically connect from a first fluid reservoir on
the first shelf to the plurality of pumps, from the plurality of
pumps to a plurality of cell culture chambers, and from the
plurality of cell culture chambers to a second fluid reservoir on
the second shelf. Preferably, the system is dimensioned for
insertion into an incubator.
[0041] In a related aspect, this disclosure provides a method for
the sterile culture of cells. The method includes providing a cell
culture system comprising a plurality of shelves stacked with a
first shelf on top of a second shelf, each of the first and second
shelves configured to receive a fluid reservoir; at least one pump;
a processor operably coupled to the at least one pump; and
[0042] a substrate sized and configured to hold a plurality of cell
culture chambers at a same time. The method further includes
loading a first fluid reservoir onto the first shelf, loading a
second fluid reservoir onto the second shelf, loading a first cell
culture chamber and a second cell culture chamber onto the
substrate, connecting the fluid and second fluid reservoirs, the at
least one pump, and the first and second cell culture chambers,
with tubing; and operating the system to culture cells inside the
first and second cell culture chambers.
[0043] In some embodiments, the first and the second cell culture
chambers includes different sizes or shapes. In some embodiments,
the system includes at least one sensor. In some embodiments, the
processor is connected to at least one sensor and is configured to
operate the pump based on a characteristic measured by the
sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] FIG. 1 shows an example of a multi-bioreactor system.
[0045] FIG. 2 shows an embodiment of a biological reactor.
[0046] FIG. 3 shows a multi-bioreactor system.
[0047] FIG. 4 shows a CAR-T/TCR workflow.
[0048] FIGS. 5-8 show comparisons of T cell expansion using
different systems.
[0049] FIGS. 9-10 show a method for co-culturing freshly cultured
dendritic cells and PBMCs or T cells, and results thereof.
[0050] FIG. 11 shows a method for forming cell-based
immunotherapeutic products.
[0051] FIG. 12 shows a system architecture according to some
embodiments.
DETAILED DESCRIPTION
[0052] The cell culture systems of the present invention
significantly improve immunotherapeutic product manufacturing,
providing flow-based immunotherapeutic production technology with
an unparalleled degree of consistency, quality, safety, economy,
scalability, flexibility, and portability. In general, cells are
grown in single-use cell culture chambers, sometimes referred to as
cartridges, which are perfused at low flow rates to achieve high
expansion without the need for filters. The system supports one or
more cell culture chambers to be fluidically coupled to one another
for carrying out the processing of a patient's cellular material to
generate an immunotherapeutic product, as described herein. It is
to be understood that the bioreactors are provided in a closed
environment in certain embodiments. Scale-up of this example
embodiment will be within the knowledge of the skilled artisan by
adding modules (e.g., biological reactors) to allow for serial
and/or parallel processing. The skilled artisan will also
appreciate that different or alternative arrangements may be
desired based on the product to be produced.
[0053] FIG. 1 shows an example of a multi-bioreactor system 900.
The system 900 includes a first cell culture chamber 820 and a
second cell culture chamber 920, which have inlets 845 and 945
connected to tubing 940 in fluid communication with a fluid
reservoir 980. The cell culture chambers have outlets 835 and 935
in fluid communication with waste reservoir 984. Pumps 910a and
910b facilitation pumping of fluid from the fluid reservoir 980 to
the cell culture chambers 820 and 920. The pumps are controlled by
processor 999 in order to perform the functions described
herein.
[0054] Another embodiment of a biological reactor 110 is shown in
FIG. 2, which provides a more detailed schematic view of the parts
of the cell culture chamber 120. It is important to note that the
cell culture platform described herein is configured to allow cell
culture chambers of different volumes, shapes, and physical
characteristics to be used. The chamber shown in FIG. 2 is
exemplary only, and other embodiments will be apparent to the
skilled artisan. As shown in FIG. 2, the cell culture chamber 120
includes a bottom surface 122 and at least one additional surface
124. The bottom surface 122 is comprised of a first material to
which cells adhere. In some embodiments the at least one additional
surface 124 is comprised of a second material that is gas
permeable. In other embodiments, which will be described in greater
detail below, the entire cell culture chamber 120, including the
surface 124, is made of the first material which gas-impermeable.
The cell culture chamber also comprises one or more inlets 126, 136
and one or more outlets 128, 138. In certain embodiments, the
biological reactor also includes at least one perfusion fluid
reservoir 132, at least one waste fluid reservoir 134, at least one
pump 140 for moving perfusion fluid through the chamber 120, as
well as associated inlets 136 and outlets 138 for transporting
fluid to and from the reservoirs 132, 134 and through the chamber
120.
[0055] With respect to the cell culture chamber 120, the first
material can be any material which is biocompatible and to which
antigen-presenting cells (APCs) or their precursors, such as
dendritic cells (DCs) or monocytes, respectively, will adhere.
During the T-cell stimulation and expansion process that occurs in
the cell culture chamber 120, mature APCs will develop and
preferably adhere to the bottom surface 122, whereas the T cells
remain in the supernatant above the bottom surface, making it
easier to separately obtain the expanded T cells.
[0056] In one example embodiment, the first material comprises
polystyrene. One benefit of using polystyrene for the bottom
surface where culturing will occur is a useful role that this
material plays in the process of generating dendritic cells from
PBMCs. Specifically, polystyrene surfaces can be used to enrich
monocytes from a heterogeneous suspension of PBMCs. This is a first
step in the culture process utilized to generate DCs by
differentiation of monocytes via culture in medium containing, for
example, IL4 and GM-CSF. The use of the same polystyrene surface
for dendritic cell production all the way through one cycle of T
cell stimulation is tremendously valuable from a bioprocess
standpoint as it eliminates a large number of transfer steps that
would otherwise be necessary, thereby allowing for a closed system
for DC-stimulated therapeutic T cell manufacturing.
[0057] The bottom surface can have a surface area comparable to
conventional well plates, such as 6- and 24-well plates (9.5
cm.sup.2 and 3.8 cm.sup.2, respectively). It is also to be
understood that the surface area can be smaller or even much larger
than conventional well plates (e.g., having surface areas
comparable to standard cell culture dishes and flasks), such as
having a surface area between about 2.0 cm.sup.2 and about 200
cm.sup.2, for example, about 2.0, 3.0, 4.0, 5.0, 6.0, 7.0, 8.0,
9.0, 10.0, 11.0, 12.0, 13.0, 14.0, 15.0, 16.0, 17.0, 18.0, 19.0,
20.0, 25.0, 30.0, 35.0, 40.0, 45.0, 50.0, 55.0, 60.0, 65.0, 70.0,
75.0, 100.0, 125.0, 150.0, 175.0, and 200.0 cm.sup.2, and any
surface area in between.
[0058] The at least one additional surface 124 can comprise any
configuration, such as one or more side walls and a top wall. In
one embodiment, as shown in FIG. 2, the side walls can be arranged
at 90 degree angles with respect to one another, such that a box
shape is formed in conjunction with the bottom surface 122. In
another embodiment, the at least one additional surface 124 forms a
curved side wall, such that the chamber 120 or a cross-section
thereof forms a cylinder, elliptic cylinder, cone, dome-like shape,
or triangular shape. It is to be understood that the above example
configurations are non-limiting and that the at least one
additional surface can have other configurations not provided in
the aforementioned example configurations.
[0059] An example configuration of a multi-bioreactor system can be
found in FIG. 3, with additional detail regarding the processes
carried out using this configuration provided below. As shown in
FIG. 3, panel B, in the event that a second bioreactor 210 is
involved, the second cell culture chamber 220 is positioned to
connect with the first cell culture 120 chamber via the outlet of
the first chamber and the inlet of the second chamber. The
connection is preferably a sterile connection. The connection
allows for the injection of sterile air into the first cell culture
chamber 120 to transfer the supernatant containing the expanded T
cells into the second cell culture chamber 220. Alternative
techniques known in the art of fluid flow may be employed to
transfer the supernatant from the first cell culture chamber 120 to
the second cell culture chamber 220. As also shown, each bioreactor
includes its own fluid and waste collection reservoirs, pumps, and
associated tubing. However, it is to be understood that the
reservoirs and pumps can be shared between bioreactors.
[0060] The system is configured to be able to perfuse the cells in
the cell culture chamber with medium, which is required for various
methods of cell culture described herein. Perfusion ensures uniform
nutrient and cytokine supply to the cellular mixture along with
sufficient gas exchange and waste removal to assist with the
formation of the cell-based immunotherapeutic product. Maintaining
consistent local concentration profile of medium and cytokines
ensures greater yields and the potential ability to speed up the
process of monocyte differentiation to DCs compared to prior art
plate-based protocols. However, the combination of adherent (DC)
and non-adherent (T cell) types, along with the high sensitivity of
DCs to mechanical forces poses challenges to the stimulation and
expansion of antigen-specific T cells, especially with respect to
the flow of fluid through the cell culture chamber. Thus, in those
embodiments in which medium and cytokines are provided via
perfusion, systems of the present invention must be able to supply
cells with nutrients and cytokines without removing cells from the
bioreactor while also taking into account the shear sensitivity of
certain antigen-presenting cells, such as DCs. Systems and methods
of the invention aim to optimize retention of autocrine/paracrine
signals favoring T cell proliferation while refreshing growth
factors and maintaining minimal physical stimulation of DCs. In
order to account for this, both the direction and the rate of
perfusion flow through the cell culture chamber must be taken into
consideration.
[0061] In certain aspects, the fluid flow rate is maintained below
the sedimentation rate of the antigen-presenting cells. As such,
the antigen-presenting cells will remain within the culture chamber
because of their mass. In other words, the antigen-presenting cells
will sink toward the bottom of the cell culture chamber and
therefore remain in the cell culture chamber.
[0062] A flow rate that is lower than the sedimentation rate can be
calculated according to Equation 1:
v_max=(.psi.d_p){circumflex over ( )}2/150
.mu.g(p_cell-p_liquid)e{circumflex over ( )}3/(1-e)
where v_max is the liquid velocity beyond which cells will be
lifted upwards, .psi. is shape factor of cells (ratio of surface
area of the cells to surface area of a sphere of equal volume; note
that cells are not perfectly spherical and this factor is expected
to be below 1), d_p is a diameter of a spherical particle of volume
equal to that of a cell, .mu. is viscosity of liquid containing
cells, g is the gravitational constant p_cell is the density of
cells, p_liquid is a density of liquid containing cells, and e is a
fraction of the volume of interest that is not occupied by
cells.
[0063] In the methods described below that involve perfusion of
medium, it should be understood that perfusion may be performed
continuously during culturing or it can occur at specific points in
time over the time period in which the cells are cultured in any
one cell culture chamber, such as, for example, 1, 2, 3, 4, 5, 6,
7, 8, 9, 10, or more times each day or week. Continuous perfusion
helps to maintain a near constant culture volume throughout the
process. Likewise, cytokines can be infused at one or more points
during culturing, such as, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9,
10, or more times, or continuously. In those embodiments, the
continuous perfusion helps maintain a consistent local
concentration profile of cytokines, which can help to ensure
greater yields and has the ability to increase the speed at which T
cells are stimulated and expanded compared to static cell culture
methods.
[0064] Perfusion parameters can be varied at any time during a
culture cycle. Example parameters include, but are not limited to,
the median flow rate, cytokine concentration, and duration of
culture cycle. Each of these parameters may have an impact on the
efficacy of T-stimulation. For example, in recent work designing
culture chambers for monocyte-diffusion to DCs, as described in
International Patent Application Nos. PCT/US2016/040042 and
PCT/US2016/60701, it has been determined that medium perfusion
rates corresponding to wall shear stress levels of 0.1 dyn/cm2 are
capable of producing DCs that are phenotypically identical to those
generated using conventional 6- or 24-well plate-based protocols.
As such, by measuring the one or more of the phenotypic and
functional measures described above during the culture cycle, the
effect of one or more perfusion parameters on efficacy can be
monitored, allowing for appropriate adjustments.
[0065] To facilitate perfusion, the system includes one or more
pumps 140. The pumps can be operably coupled to the cell culture
chamber 120 for perfusing perfusion medium into the cell culture
chamber. The bioreactors 110 can also include one or more fluid
reservoirs 132. The fluid reservoirs 132 are in fluidic
communication with the cell culture chamber 110 and can be operably
coupled to one or more pumps 140. One or more tubes for connecting
the fluid reservoirs to the pumps and cell culture chamber are also
provided. In certain aspects, the one or more pumps are configured
for pumping fluid from the fluid reservoir, through the cell
culture chamber, and into the waste collection reservoir. In the
example embodiment shown in FIG. 2, fluid moves from the fluid
reservoir 132, through tubing 152 to the pump 140 and into the cell
culture chamber 120 via inlet 136, back out of the cell culture
chamber 120 via outlet 138, through tubing 154, and into the waste
collection reservoir 134.
[0066] In certain embodiments, the fluid reservoir and/or waste
collection reservoir can each be provided as one or more sealed
bags or containers fluidically coupled to the chamber. Each
reservoir contains an inlet port and an outlet port, or an outlet
port and a vent fluidically coupled to the inlet of one or more
cell culture chambers. In some embodiments, Luer connectors and
silicone gaskets cut to fit around the Luer connectors can be used
to prevent leakage through either or both of the inlet or outlet.
In some embodiments, the sealed reservoirs can be connected to the
cell culture chamber using a sterile tube welding device that
creates a fluidic connection without exposing either vessel to the
outside environment and maintaining sterility. As will be discussed
in greater detail below, this allows methods of the invention to be
performed in a closed system.
[0067] Due to the small size and portability of the disclosed cell
culture systems, they can be easily used in conjunction with a tube
welding device. Systems of the invention can be easily lifted and
carried into proximity with a tube welder in order to make the
necessary sterile connections. The size and configuration of the
cell culture systems also makes them compatible with standard
incubators. The cell culture systems are sized and configured to
fit on a single shelf inside a conventional incubator, such that
the disclosed processes can be carried out therein. Multiple
instruments can fit in a single incubator, depending on the
configuration. Conditions within the incubator include sustained
temperatures of 37.degree. C. and 95-100% humidity. Thus, the
materials chosen must have the integrity to withstand these
conditions, given that the materials (including fluids and
biologics) tend to expand under such conditions. Furthermore, in
some circumstances, conditions within the incubator remain stable,
and automated recording of the temperature is possible to have
knowledge of temperature fluctuations to correlate with any
aberrations in the reactions performed in the incubator.
[0068] Accordingly, any supply of power should not change the
environment within the incubator. For example, certain pumps
generate heat. Accordingly, in one embodiment, the pumps are housed
separately from the biological reactors, but are still in fluidic
and operable communications with the reactors. In another
embodiment, the pumps are directly attached to the biological
reactors and located within the incubator, but are heat free or are
operably connected to a heat sink and/or a fan to dissipate the
heat. In another embodiment, the pumps run on a duty cycle to
reduce the amount of heat generated. Regardless of the
configuration, the pumps are operably coupled to the biological
reactors, and, in turn, the cell culture chambers. In some
embodiments the system also includes a heater for controlling the
temperature of the cell culture reservoir and optionally the fluid
reservoir. In such a configuration, no incubator is required, and
the system can operate autonomously, with only a source of
electrical power. If the system lacks a heater, it can be operated
inside of a cell culture incubator.
[0069] Additional details regarding perfusion-based automated cell
culture systems, such as small scale culture system for endothelial
cell culture with on-board reagent storage and perfusion enabled by
an on-board disposable peristaltic pump and a larger scale culture
system for dendritic cell generation from monocytes using chambers
with polystyrene bottom surfaces, can be found in international
patent publications WO 2017/004169; WO 2017/079674; and WO
2018/005521; as well as U.S. patent application Ser. No.
16/539,916; each of which is incorporated herein by reference in
their entirety.
[0070] Systems, or devices, of the invention are modular and
capable of fluidic connection to other similar devices in series
(i.e., with fluid flowing from one device into another) and/or in
parallel, and may also be so configured as to physically stack with
one another or be capable of physical arrangement within a related
device such as an incubator. The modular design of the system
specifically allows for modules to be flexibly switched in and out
depending on a desired process to be included within the
system.
[0071] Fluidic devices of the invention, including the biological
reactors comprising cell culture chambers, can be provided in
either a microfluidic embodiment (i.e., wherein one or more
channels or chambers therein has a dimension in the range of from
about 1 .mu.m to about 999 .mu.m) or a macrofluidic embodiment
(wherein all of the channels or chambers therein have dimensions of
about 1 mm or more), or both.
[0072] The fluidic devices can further include additional fluid
channels or compartments, gaskets or seals, mixing zones, valves,
pumps, vents, channels for pressurized gas, electrical conductors,
reagents, ports, and tubing as required by a particular design.
They also may contain one or more control modules, transmitters,
receivers, processors, memory chips, batteries, displays, buttons,
controls, motors, pneumatic actuators, antennas, electrical
connectors, and the like. The devices preferably contain only
materials that are nontoxic to mammalian cells and that are
compatible with sterilization by the use of alcohol and/or heat or
other means, such as exposure to gamma radiation or ethylene oxide
gas.
[0073] The materials of equipment are chosen with the appropriate
chemical compatibility under different temperature and pressure
rating specific to each process. Additionally, the choice of pumps
implemented in the device, such as syringe, peristaltic, pressure,
and rotary pump, ranges from a nL to a mL in flow rates and 10 to
10,000 psi in pressure depending on the flow and pressure
requirements for the different functions.
[0074] Systems of the invention can also include one or more sample
solution reservoirs or well or other apparatus for introducing a
sample to the device, at various inlets of the modules, which are
in fluid communication with an inlet channel. Reservoirs and wells
used for loading one or more samples onto the fluidic device of the
present invention includes but are not limited to, syringes,
cartridges, vials, Eppendorf tubes and cell culture materials
(e.g., 96 well plates).
[0075] Where useful, surfaces of the devices can be made more
hydrophilic, such as by exposure to a plasma, or can be coated with
one or more gels, chemical functionalization coatings, proteins,
antibodies, proteoglycans, glycosaminoglycans, cytokines, or cells.
Fluidic devices of the invention are preferably devoid of fluid
leaks under operating conditions and capable of sterile operation
over a period of days to weeks. Fluidic devices of the invention
also include a sampling mechanism that allows fluid to be removed
from the system for testing without introducing new material or
contaminants to the system.
[0076] In certain aspects, at least part of the cell culture system
comprises disposable components, some or all of which can be housed
within a non-disposable frame. In other aspects, all components of
the system are disposable. Furthermore, in some embodiments, the
cell culture system includes a sample tracking component for
tracking and documenting patient material.
[0077] At least one step, and sometimes a plurality or all steps,
during the manufacturing process are monitored for product
characteristics (e.g., purity and polymorphic forms) using a
variety of inline process analytical tools (PAT) or miniaturized
micro-total analysis system (micro-TAS).
[0078] As described above, the cell culture systems of the present
invention are capable of controlling the direction and flow of
fluids and entities within the system. Systems of the invention can
use pressure drive flow control, e.g., utilizing valves and pumps,
to manipulate the flow of cells, reagents, etc. in one or more
directions and/or into one or more channels of a fluidic device.
However, other methods may also be used, alone or in combination
with pumps and valves, such as electro-osmotic flow control,
electrophoresis and dielectrophoresis (Fulwyer, Science 156, 910
(1974); Li and Harrison, Analytical Chemistry 69, 1564 (1997);
Fiedler, et al. Analytical Chemistry 70, 1909-1915 (1998); U.S.
Pat. No. 5,656,155).
[0079] Systems of the invention can also include or be operably
coupled to one or more control systems for controlling the movement
of fluid through the system; monitoring and controlling various
parameters, such as temperature, within the systems; as well as
detecting the presence of cell-based immunotherapeutic products,
quantity of product (directly or indirectly), conversion rate, etc.
The system may also be equipped with numerous classes of software,
such as an advanced real-time process monitoring and control
process, allowing for feedback control, as well as processes that
allow integration and scale-up given reaction and purification
results obtained using the system.
[0080] In certain embodiments, the system includes a combination of
micro-, or macrofluidic modules and tubing that are interchangeable
in terms of channel dimensions, flow geometry, and
inter-connections between the different modules of the device. Each
module and tubing may be designed for a specific function. In one
embodiment, all of the modules within the system are designed for
cell culturing and T-cell stimulation. In other embodiments, the
modules with the system are designed for different functions, such
as tissue processing, dendritic cell generation, cell culturing,
concentration, and/or purification, all integrated for the
continuous manufacturing of an immunotherapeutic product. Both
homogenous and heterogeneous processes are considered which are
suitable for flow application. These processes are designed and
optimized with respect to the starting materials and operating
conditions, such as temperature, pressure and flow rates so as to
not readily clog the system during the flow process.
[0081] Gas-Impermeable Cell Culture Chambers
[0082] In some embodiments, the cell culture chambers of the
disclosed system are made of a gas-impermeable material. The
gas-impermeable material is biocompatible and is a material to
which dendritic cells will adhere. In one example embodiment, the
gas-impermeable material comprises polystyrene, which as described
above is useful for enriching monocytes from a heterogeneous
suspension of PBMCs. The entire cell culture chamber being made of
the gas-impermeable material offers a larger surface area to which
cells can adhere and increases the sterility of the system.
[0083] A gas-impermeable cell culture chamber can be substantially
the same as the chamber 120 shown in FIG. 2 and can have any
volume, shape, size, and physical characteristic described above,
with the exception that the additional surface 124 and all other
surfaces of the chamber 120 are made of the same material as the
bottom surface 122. In some embodiments, the top, bottom, and all
side walls of the chamber 120 are gas-impermeable. The bottom
surface of the gas-impermeable cell culture chamber can have a
surface area comparable to conventional well plates, such as 6- and
24-well plates (9.5 cm.sup.2 and 3.8 cm.sup.2, respectively). It is
also to be understood that the surface area can be smaller or even
much larger than conventional well plates (e.g., having surface
areas comparable to standard cell culture dishes and flasks), such
as having a surface area between about 2.0 cm.sup.2 and about 200
cm.sup.2, for example, about 2.0, 3.0, 4.0, 5.0, 6.0, 7.0, 8.0,
9.0, 10.0, 11.0, 12.0, 13.0, 14.0, 15.0, 16.0, 17.0, 18.0, 19.0,
20.0, 25.0, 30.0, 35.0, 40.0, 45.0, 50.0, 55.0, 60.0, 65.0, 70.0,
75.0, 100.0, 125.0, 150.0, 175.0, and 200.0 cm.sup.2, and any
surface area in between.
[0084] Certain modifications need to be made to the system
described above when the chamber is not permeable to gas. For
example, in such embodiments where gas does not flow through one of
the surfaces of the cell culture chamber, the gas exchange between
cells and the medium must be facilitated in another way. The cell
culture chamber comprises one or more inlets 126 and 136 and one or
more outlets 128 and 138. The inlet and outlet openings can be
fluidically coupled to tubing, which is sealed with the respective
opening. The inlets and outlets are thereby connectable to a
perfusion fluid reservoir and a waste fluid reservoir with
corresponding pumps for moving perfusion fluid through the chamber.
The inlets and outlets can be located in any surface of the
chamber. In some embodiments, they are located in the top of the
chamber. The tubing is preferably high-permeability tubing, In
order to effectuate gas exchange, the medium can exchange gas prior
to entry into the chamber and after leaving the chamber through the
high-permeability tubing. Gas is therefore effectively brought into
the chamber through the one or more inlets and removed through the
one or more outlets. The inlets or the tubes connected thereto can
include a filter such as a 0.2 micron filter, for filtering liquid
or air entering the cell culture chamber.
[0085] Gas flow is affected by perfusion rates, the parameters of
which can be controlled as described above. By exchanging gas via
the high permeability tubing, the system maintains the ability to
achieve the required levels of gas exchange without requiring the
chamber to be gas permeable. Methods of cell culture can be
performed in a completely gas-impermeable chamber, with inlets 126
and 136 and outlets 128 and 138 for perfusion and gas flow. In
methods embodiments, the gas-impermeable cell culture chambers can
be used to culture cells by loading cells into the chamber and
perfusing them by flowing cell culture medium in and out of the
chamber via the inlets and outlets. The perfusion flow provides
nutrients as well as gas exchange to the cell culture. Because flow
through the chamber is laminar, some methods may require additional
shaking, such as for cell harvesting. However, given the size and
configuration of the disclosed systems, the entire system can be
placed on an orbital shaker as needed.
[0086] Another advantage of gas-impermeable embodiments is that
they are easier to manufacture because they have fewer different
parts and materials. They can be made as large or small as needed.
The gas impermeable chamber can be integrally formed or it can be
formed from multiple parts. For example, it can be formed out of a
single piece of material by traditional manufacturing processes or
additive manufacturing processes such as 3D printing. In
embodiments, a plurality of members, each made of the
gas-impermeable material, are joined together using methods known
in the art, such as mechanical fastening, adhesive and solvent
bonding, and welding, such as ultrasonic welding.
[0087] Interchangeability of Cell Culture Chambers
[0088] Cell culture systems of the present invention are configured
to be able to connect with cell culture chambers of various sizes
and shapes. The cell culture system can include a fluid reservoir,
a waste reservoir, and one or more pumps for controlling fluid flow
to and from the reservoirs. The cell culture system also has an
area configured to receive one or more cell culture chambers of
different shapes and sizes. One or more tubes fluidically connect
the fluid reservoir, the cell culture chambers, and the waste
reservoir. The pumps are configured to move fluid through the
tubes.
[0089] Different cell culture chamber sizes can be used for
different purposes, or in combination with each other. The size can
be selected based on the desired cell output, or different
proportions of reagents needed. For example, small cartridge sizes
can be useful for research, pre-clinical uses, or process
development. Large cartridges are a higher capacity version with
the same architecture.
[0090] The height of the one or more cell culture chambers can
vary. For example, and not limitation, an example range of cell
culture chamber heights includes heights of anywhere from 0.5 mm to
100 mm, such as 0.5, 1.0, 2.0, 3.0, 4.0, 5.0, 6.0, 7.0, 8.0, 9.0,
10.0, 15.0, 20.0, 25.0, 30.0, 35.0, 40.0, 45.0, 50.0, 55.0, 60.0,
65.0, 70.0, 75.0, 80.0, 85.0, 90.0, 95.0, 100.0 mm, or more, or any
height therebetween. In certain embodiments, the heights of the
chamber can be comparable to liquid heights in cultures that are
typically performed in 6- and 24-well plates, such as between 2 and
6 mm, with a volume capacity of about 0.8 mL to 6 mL. In other
embodiments, the cell culture chambers will be of larger size, such
as between 10 mm and 50 mm, with a culture surface of about 50
cm.sup.2. In some embodiments the cell culture chamber has a volume
capacity of between about 1 mL and about 100 mL, and may be
approximately 5, 10, 20, 25, 30, 40, 50, 60, 70, 80, or 90 mL, or
anywhere in between. In other embodiments the cell culture chamber
has a volume capacity of between about 100 mL and about 1,000 mL,
for example 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1,000
mL. In a particular embodiment a cell culture chamber has a
capacity of 210 mL.
[0091] The interchangeability of cartridges with the present
invention allows scaling up during a cell growth procedure using
the same system. This avoids the need to switch to a different cell
culture system in order to continue growing cells. For example, to
manufacture a batch size of about 2 billion cells, the system can
start with a small cartridge with a capacity of about 25 mL, and
then scale up to a large cartridge with a capacity of about 210 mL.
This interchangeability means that more parts of the process can be
done on the same system, from activation through fill and finish.
Depending on the needs of a particular protocol, the system is
operable with, for example, two large (approximately 210 mL) cell
culture chambers, two small (approximately 25 mL) cell culture
chambers, or one of each. Since each inlet and outlet can be
connected to any size chamber, the system is capable of scaling up
or scaling down as needed.
[0092] With reference once again to FIG. 1, the system 900 includes
a platform 950 configured to support one or more cell culture
chambers 820 and 920. Regardless of shape or size, the cell culture
chambers can be connected via tubes 940. In this way, cell culture
chambers of different shapes and sizes are compatible with the
system. The cell culture chambers can be arranged in different
configurations on the platform, such as positioned side-by-side or
stacked. In embodiments, the tubes 940 are integrally formed with
the chamber. The tube and the chamber body can be joined together
using the same manufacturing methods discussed above. In one
embodiment, the cell culture chamber is manufactured with at least
a portion of the material in the side and/or top walls cut out to
allow for the formation of the one or more inlets or outlets. In an
example arrangement, a tube can be separately inserted into the
openings to form a seal with the vessel. It is to be understood
that the aforementioned configurations are only examples and that
other configurations for joining the chamber and one or more tubes
are also contemplated embodiments of the present invention.
[0093] Interchangeability is facilitated in part by using sterile
tube connections to couple the various vessels and chambers of the
system. The sterile tubes are preferably connected using a sterile
tube welder. Generally a sterile tube welder is a device that can
receive two tubes, secure them in place, and then cut them with a
hot blade, realigns them so that the first tube and second tube are
aligned, and melts the two cut ends together when the blade is
retracted. Sterile tube welders for use with the present invention
can be any commercially available sterile tube welder, including
SCD.RTM. IIB from Terumo BCT, Inc. (Lakewood, Colo.); the
Vante.RTM. 3690 from Vante BioPharm (Tucson, Ariz.); and the
TCD.RTM. from Genesis BPS.TM. (Ramsey, N.J.).
[0094] As will be described in greater detail below, in certain
embodiments the system is functionally closed. The closed system is
maintained by all of the transfers being done using sterile tube
welding. For example, cells may be stored in a sterile bag, which
is then connected to a sterile cell culture chamber. The cells can
be flowed into the cell culture chamber while maintaining
sterility. The tube connectivity allows cell seeding, washing, and
harvesting to all be done on the same device under sterile
conditions. By using the sterile tube welder, one bag does not have
to be disconnected before connecting another.
[0095] The above description focuses on the system components and
various possible configurations. The following description focuses
on certain processes that can be carried out using systems of the
invention.
[0096] CAR-T and TCR Processes in a Closed System
[0097] The cell culture systems described above are useful for
methods of producing CAR-T and TCR transduced T cells. A
visualization of a CAR-T/TCR workflow is shown in FIG. 4. The
disclosed system can be used to perform several of the steps of the
workflow in a closed system, including genetic modification, cell
expansion, cell washing and concentration, and cell formulation.
Prior known methods used in the industry producing CAR-T and TCR
transduced T cells are not performed in a closed system. Commonly
used polystyrene T flasks have to be opened and closed to perform
transfers, and are therefore subject to potential contamination.
The present invention uses closed and interchangeable cartridges
made of solid polystyrene, which allows protocols designed for T
flasks to be easily reformatted to be done on the disclosed sterile
system.
[0098] In some embodiments, a method of the invention involves
flowing cell culture medium into a culture chamber with T cells,
and perfusing the T cells to transduce them with a transduction
reagent such as an inactive virus expressing CAR or TCR, for
example. The perfusion fluid may include an activation reagent to
expand the cells. In some embodiments the transduction and/or
activation reagents are premixed with the cells, and in other
embodiments they are from a separate sterile bag or vessel. The
bags can be connected through sterile welding means as described
above, and the reagents can be flowed into the bag by gravity or by
a pump. In some embodiments, the cell culture chambers are filled
completely with little or no headspace.
[0099] The cells are grown for up to about 3 days, during which
time they are allowed to take on CAR, TCR, and are sustained by the
perfusion medium. The cells form a sediment in the chamber and the
perfusion rate is maintained low enough to prevent the cells from
flowing out of the cartridge. The transduced cells are expanded in
the culture chamber and then can be transferred to a larger culture
chamber, which is connected via a sterile tube, for further
expansion. Using methods of the invention a 7-day expansion in a
small cartridge (25-mL volume) can yield about 500 million to one
billion T cells, and a large cartridge (210-mL volume) can yield
about one to three billion T cells.
[0100] The connection with the perfusion bag is detached and a
harvest bag is attached. The cells are then drained into the
harvest bag. In embodiments, a buffer bag can be connected by the
same methods and used to perform one or more washes of the cells
before they are removed into the harvest bag. The volume of liquid
that the cells are in can be increased or decreased, by draining
one liquid, adding another, and resuspending the cells in the new
volume of liquid. In some embodiments, the system can be drained to
remove built-up lactic acid. As the cell culture expands, lactic
acids builds up and may not be removed fast enough through
perfusion alone. A solution is to drain the medium to reduce the
total volume (by perhaps 90-95%) without removing the cells, and
then perfuse with fresh medium. In some embodiments, the medium can
be replaced with a different cell culture medium or
cryopreservation medium.
[0101] The cell culture chambers are connected in a closed system
such that the entire method is performed in a closed environment
without the need to expose the media to air by opening any of the
vessels when transferring. As has been mentioned, all of the
connections and disconnections of the method can be done with a
sterile tube welder.
[0102] Unlike the prior art, the disclosed method of activation,
transduction, and expansion are performed in a closed sterile
system. With the interchangeability described above, a user can
scale up to a batch of up to 10-20 billion expanded cells, all in a
closed environment. In some embodiments, the methods may be used to
prepare a batch for manufacturing on a larger bioreactor system. In
conventional CAR-T manufacturing, batches of 10 billion or more
cells are needed. The presently disclosed systems and methods can
perform the upstream steps of activation, transduction, and initial
expansion, prior to transferring 1 billion or more cells to a
larger expansion system, such as XURI.TM. available from GE
Healthcare (Chicago, Ill.). This capability makes the systems
highly compatible with non-magnetic activation reagents.
[0103] FIGS. 5-6 show an example of the comparison between a T cell
expansion conducted with the presently disclosed system, known as
BATON.TM. from Flaskworks, LLC (Boston, Mass.), and another
commercially available T cell expansion platform G-REX.RTM. from
WilsonWolf (St. Paul, Minn.). FIG. 5 shows a graph of the
fold-expansion using BATON.TM. over 9 days with PBMCs stimulated
with DYNABEADS.RTM. from Thermo Fisher (Waltham, Mass.) run in a 25
mL cartridge. The robust fold-expansion achieved with BATON.TM. is
comparable to that of G-REX.RTM..
[0104] FIG. 6 shows the number of cells on day 0 and day 7, using
both systems. With BATON.TM., approximately a billion cells were
obtained from 40 million T cells in seven days in a 210 mL
cartridge in accordance with the present disclosure. The phenotype
is predominantly central memory. As further shown in FIG. 7,
phenotypic profiles are comparable between BATON.TM. and
G-REX.RTM.. The figure also compares T75 flasks available from
Corning Inc. (Corning, N.Y.). As shown, both BATON.TM. and
G-REX.RTM. generated equivalent CD4/CD8 ratios for Day 9.
[0105] As shown in FIG. 8, the cytotoxicity of T cells produced
with BATON.TM. is comparable to that of G-REX.RTM.. The effector
cells were expanded for 9 days, and the target cells were Jurkat T
cells. Cells were mixed at a 10:1 ratio of effector-to-target and
incubated at 37.degree. C. at 5% CO.sub.0 for 24 hours. The medium
was RPMI 1640 (ATCC)+15% FBS. The Day 5 and Day 7 cells from all
three groups were comparable in cytotoxicity.
[0106] Neoantigen Process on a Closed System
[0107] The disclosed systems are also useful in a workflow for
producing neoantigen-targeting T cells. This class of therapeutics
involves the co-culture of antigen-presenting cells stimulated with
libraries of tumor-specific peptides and autologous T cells.
Manufacturing of neoantigen presenting cells is more complex than
CAR-T. Unlike CAR/TCR, the present method can pursue a library of
targets rather than just one. It requires certain capabilities
provided by the presently disclosed systems which are not available
from prior art systems.
[0108] The present system generates fresh dendritic cells from
patient monocytes. The system also is configured to co-culture
dendritic cells with patient PBMCs or T cells and deliver
stimulated T cells. The system can perform multiple cycles of
co-culture with freshly generated dendritic cells to avoid
competing effects between different antigens. Parallel processing
of dendritic cells and T cells to facilitate this process will be
described in greater detail below. The typical dose sizes for
neoantigen therapies are about 200 million T cells, which can be
handled by the disclosed system in either a small (approximately 25
mL) or large (approximately 210 mL) cartridge.
[0109] Unlike prior art methods, systems of the invention
facilitate all of the above in a closed environment. The method
utilizes the interconnected cell culture chambers of the present
system. Purified monocytes are introduced to one of the cell
culture chambers, and purified T cells are introduced to the other.
The monocytes are perfused with cell culture medium to produce
dendritic cells, which are then contacted with antigen material
comprising tumor-specific peptides. This produces mature dendritic
cells presenting tumor-specific peptides. T cells are transferred
into to chamber containing the mature dendritic cells to co-culture
them with the T cells. Co-culturing produces neoantigen-targeting T
cells. After one cycle of stimulation via co-culture, the T cells
can be removed and optionally flowed into a second chamber
containing freshly generated mature dendritic cells to perform a
second co-culture. The second batch of dendritic cells can be
produced asynchronously from the dendritic cells generated in the
first chamber.
[0110] In embodiments, mature dendritic cells are generated in a
first chamber and then T cells added to the first chamber and
co-cultured. T cells from the first chamber are then moved to a
second chamber where they are co-cultured with freshly generated
dendritic cells that are stimulated with either the same or a
different set of peptides. The expanded T cells can then be moved
back to the first chamber where yet another batch of fresh mature
dendritic cells stimulated with either the same or different set of
peptides await.
[0111] The T cells can be transferred back and for the between two
connected chambers any number of times as desired. This can be
particularly useful for stimulating DCs with several different
peptides. For example, if one has a library of 20 or so peptides
with which the DCs need to be stimulated, attempting to stimulation
the DCs with all peptides at once would result in insufficient
stimulation because of competing effects between the peptides. Some
peptides have greater effect and/or affinity than others.
Performing the stimulation in stages, for example, stimulating a
batch of DCs with five peptides in a first co-culture, and then
stimulating the next batch of DCs with five different peptides in a
second co-culture, and so on. In other embodiments, multiple
stimulation cycles can be done with a single, small group of
peptides. In nonlimiting embodiments, the T cells can be
transferred 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, or 25 times. Each
co-culture can involve DCs stimulated with the same or different
peptides.
[0112] The entire method is performed within the closed system of
the present disclosure, thereby maintaining sterility throughout
the method. Like the other disclosed methods, the culture chamber
connections can be achieved with sterile tubes that are connected
with a tube welder. This maintains that sterility of the cell
culture medium that is provided in a sterile vessel. In various
embodiments, the T cells can be transferred between chambers on the
same instrument or transferred between chambers on separate
instruments.
[0113] After the co-culture is complete, fluid is drained from the
chamber, and the neoantigen-targeting T cells can be washed with a
buffer and resuspended in a cryopreservative and/or harvested in a
harvest bag, which is also connected in a closed manner.
[0114] FIG. 9 shows a schematic flowchart of a method for
co-culturing freshly cultured dendritic cells and PBMCs or T cells
on the closed system of the present invention. Using sterile welded
connections, the disclosed cell culture system provides automated
seeding, culture, and cell harvesting. As shown in the workflow,
monocytes are seeded at day 0, and differentiate into dendritic
cells over days 0-6. At day 6, allogeneic PBMCs or T cells are
added. Dendritic cells enable T cell expansion from PBMCs. The
expanded T cells are harvested on day 13.
[0115] Expanded T cells produced with the disclosed methods show a
robust cytotoxic ability. Results of an example performed using the
workflow is shown in FIG. 10. The target ratio of CD 8+ T cells to
Jurkat cells was 1:1, with experiments performed using 1-3 million
harvested cells. Jurkat cells were stained with PKH67 prior to the
assay. Cells were incubated for 1 day, and all cells were stained
with CD3 and Annexin V post-assay. The resultant dead Jurkat cells
are shown in FIG. 10.
[0116] Parallel Processing of Dendritic Cells and T Cells
[0117] The process for forming cell-based immunotherapeutic product
requires co-culturing two types of cells. With the presently
disclosed systems, these cells can be generated in parallel for
more efficient generation of antigen-specific T cells. In brief,
dendritic cells are produced from monocytes and matured by contact
with antigen material, and T cells are activated and then
co-cultured with the DCs. In prior art methods, this method would
require several manual steps. The current system however can
produce the two cell batches in parallel in a closed system. Using
the systems disclosed herein, dendritic cells are produced in one
chamber and, in parallel, T cells are stimulated in another
connected chamber. Monocytes are perfused in a first chamber to
produce DCs, which are contacted with antigen material to mature
them. Activated T cells from another connected chamber are flowed
into the first chamber to contact the DCs and further culture the T
cells. Like in the other methods, the chambers are connected via a
sterile tube, so that the method is performed in a substantially
closed system. The T cells can be collected by flowing them into a
collection vessel and/or transferred to a cryopreservation medium,
while still in a closed system configuration.
[0118] Reference is made to FIG. 11 which shows a general overview
of a process for forming cell-based immunotherapeutic products. The
steps in generating cellular therapeutic product in accordance with
certain embodiments of the present invention include the
co-culturing of stimulated antigen-presenting cells (e.g. DCs) with
T cell containing cells in a biological reactor containing a cell
culturing chamber. A supernatant containing expanded therapeutic T
cell products is generated during culturing. In certain aspects, in
order to produce a quantity of antigen-specific T cells sufficient
to elicit a therapeutic response in a patient, the T cells must
undergo additional culturing in one or more additional cell
culturing chambers. In order to effectuate this additional
culturing, the transfer of supernatant from the culture chamber in
which the supernatant was generated to a subsequent cell culture
chamber containing a fresh supply of antigen-presenting cells must
occur. The transfer of supernatant between cell culture chambers
may involve the introduction of a gas flow into the first cell
culture chamber that transfers the supernatant comprising the first
cell product through a fluidic connector and into the new cell
culture chamber. Furthermore, during each of the culturing steps,
perfusion fluid containing, for example, medium and cytokines, can
be perfused to the chambers. In certain aspects, the perfusion
fluid flows through the chambers along a vertical flow path so as
to ensure that the cells remain within the chamber during
culturing. One or more subsequent cell culture chambers can be
connected to the system with each chamber containing a new batch of
antigen peptide-pulsed autologous antigen-presenting cells.
[0119] In order to stimulate and expand antigen-specific T cells,
the process begins with a co-culture of T cell containing cells
with antigen-presenting cells (APCs) obtained from the same
individual in a cell culture chamber. In a particular embodiment,
the T cell containing cells include peripheral blood mononuclear
cells (PBMCs) and the APCs include DCs. The T cell containing cells
and APCs can be provided to the cell culture chamber in a ratio
(T-cell containing cells:APCs) from about 1000:1 to 1:1000 of
about, such as, for example and not limitation, 1000:1, 900:1,
800:1, 700:1, 600:1, 500:1, 400:1, 300:1, 200:1, 100:1, 75:1, 50:1,
25:1, 20:1, 15:1, 10:1, 5:1, 4:1, 3:1, 2:1, 1:1, 1:2, 1:3, 1:4,
1:5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:15, 1:20, 1:50, 1:75; 1:100,
1:200: 1:300, 1:400, 1:500, 1:600, 1:700, 1:800, 1:900, 1:1000, or
any ratio therebetween. In one aspect, a ratio of 10:1 is
preferred.
[0120] In order to initiate stimulation and expansion of T cells
from the interaction of APCs with T-cell containing cells, the APCs
need to be stimulated. This can be done through the use of one or
more stimulatory molecules. In certain embodiments, the stimulatory
molecule is non-tumor specific. In other embodiments, the
stimulatory molecule is tumor specific. For example, the
stimulatory molecule can be chosen from one or more characteristics
of an individual's tumor, such as different antigen peptides. In
some embodiments, the stimulatory molecule is preferably added only
in the beginning of a culturing cycle. The stimulatory molecule can
be added over a period of only about a few minutes, an hour, a few
hours, or longer. In one preferred embodiment, the stimulatory
molecules are added over about an hour time period.
[0121] The co-culturing of APCs and T-cells takes place in a
culture medium. Example culture media include, but are not limited
to, RPMI medium, and Cellgenix.RTM. medium. Any other suitable
culture medium known in the art can be used in accordance with
embodiments of the present invention. Cytokines such as IL-4 and
GM-CSF can also be added to the culture medium.
[0122] It is not usually sufficient to do only one co-culture. The
disclosed system allows T cells to be pulled out in a suspension.
Here T cells can be re-stimulated with fresh dendritic cells and
multiple co-cultures can be done in the closed system. With the
parallel processing methods of the present invention, the
cartridges can be connected in a chain and cells can be pushed from
one cartridge to another. One reactor containing mature, adhered
DCs will be loaded with PBMCs and subjected to a stimulation cycle
with perfusion of medium and cytokines. With parallel processing,
the expanded T-cells can be continuously exposed to fresh DCs being
produced in the first cell culture chamber by being pulsed with
antigen peptides. The stimulation process can continue for as long
as needed in order to generate a sufficiently large number of cells
for a therapeutic dose of T cells.
[0123] Connecting multiple chambers together via a sterile
connection can involve the configuration of multiple chambers as
discussed above with respect to FIG. 3. The connection allows for
the injection of sterile air into the first cell culture chamber to
transfer the supernatant containing the expanded T-cells into the
second cell culture chamber. In certain embodiments, the one or
more biological reactors can be provided in a system containing
modules for effectuating various other processes prior to,
concurrent with, or subsequent to the process occurring within the
cell culture chambers of the biological reactors.
[0124] One cartridge can be transferred into harvesting bag or into
a new cartridge via sterile welding and sealing. In some
embodiments, dendritic cells can be generated and then harvested
and cryopreserved, and used on demand. Meanwhile, the system can
independently run a second cartridge for fresh dendritic cell
generation.
[0125] In certain aspects, computational modeling approaches are
used to optimize the interaction of T-cells with antigen-presenting
cells. Computational models in accordance with the present
invention take into account the impacts of perfusion and the
optimal time required for stimulation, and incorporate both
particle interaction-based as well as kinetic parameter-based
approaches. Example particle interaction-based and kinetic
parameter-based approaches are known in the art, some of which are
described herein. For example, with respect to particle
interaction-based approaches, Day and Lythe describe the time
required for a T cell to find an APC on the surface of a lymph node
using the following expression, where D is the diffusivity of the T
cell, and b is the radius of the APC located centrally within a
spherical lymph node of radius R. See Day et al., Mathematical
Models and Immune Cell Biology; 2011
.tau. ' = 1 4 3 .times. .pi. .function. ( R 3 - b 3 ) .times.
.intg. b R 4 .times. .pi. .times. r 2 .times. F .function. ( r )
.times. dr = R 3 3 .times. Db - 3 5 .times. R 2 D + 2 3 .times. b 2
D + ##EQU00001##
With respect to kinetic parameter-based approaches, Valitutti has
developed a model of the interactions between T-cells and
antigen-presenting cells, as shown in FIG. 9. Valitutti et al.,
FEBS Lett. 2010. However, such interactions have not been modeled
within the context of a culture chamber or bioreactor.
[0126] By incorporating both particle interaction-based as well as
kinetic parameter-based approaches into the computational models of
the present invention, automated determination and monitoring of
the optimal perfusion rate of a perfusion fluid (e.g., cytokine
infused medium) for maximizing the probability of two cell types
contacting each other within the cell culture chamber can be
achieved.
[0127] For example, in certain embodiments, a cell culture system
is provided that includes a cell culture chamber and a central
processing unit comprising memory containing instructions
executable by the central processing unit. In certain aspects, the
instructions cause the system to receive as a first input data
comprising a size of the cell culture chamber, receive as a second
input data comprising a first concentration of a first cell type
and a second concentration of a second cell type in one or more
fluids that will be introduced into the cell culture chamber, and
calculate, based on the first and second inputs, a perfusion rate
of a perfusion fluid that will be introduced into the cell culture
chamber that maximizes a probability of the first cell type and the
second cell type contacting each other within the cell culture
chamber. Additional details regarding computer systems for
implementing the methods of the present invention within cell
culture systems are provided below.
[0128] In some aspects, the system also includes one or more pumps
operably coupled to one or more perfusion fluid reservoirs and
operably coupled to the central processing unit, such that the
central processing unit also controls the perfusion rate of the
perfusion fluid by controlling the one or more pumps.
[0129] Recycling Medium
[0130] Cell culture medium and supplements (such as cytokines) are
expensive, and used medium often has residual nutrients in it,
which get discarded. Recognizing this, the disclosed systems
provide ways to recapture some of the partially used medium and
recycle it. In certain methods of the invention, cells are cultured
in one of the disclosed cell culture chambers, wherein cell culture
medium is flowed through the cell culture chamber. Generally the
fluid flows into an inlet and out of an outlet. A portion of the
cell culture medium that has already flowed through the cell
culture chamber and out of the outlet is recycled back into the
cell culture chamber during the cell culturing process.
[0131] In order to determine how much and/or which portion of used
medium should be returned to the cell culture chamber, the
invention measures one or more parameters such as nutrient content
or pH of the used medium prior to recycling. The measured nutrients
can be glucose, lactate, dissolved oxygen, or cell metabolites. The
parameter of interest is measured and a processor determines
whether the parameter meets a predetermined threshold that
indicates that it can be recycled. If so, the medium is sent back
into the cell culture chamber.
[0132] The used medium can be recycled on its own or it can be
combined with a bolus of fresh medium. If, on the other hand, the
used medium does not meet the predetermined threshold, it is
discarded. In some embodiments a valve operates to direct the used
medium either to a waste reservoir or back into the cell culture
chamber.
[0133] In various embodiments, the recycling can be performed at
any frequency. For example, the one or more sensors can check the
used medium at regular intervals, such as every second, every
minute, every 10 minutes, every hour, etc. In other embodiments,
the one or more sensors can operate continuously by measuring the
medium as it goes through a waste line. In some embodiments, the
recycling is controlled through feedback from external filters or
sensors that monitor the waste medium to determine if it can be
reused or if it is spent. In some embodiments, an in-line sensor is
embedded in the system to monitor waste medium and determine if it
can be recycled.
[0134] Recycling achieves the goal of enabling gas exchange between
the exterior of the cell culture chamber and the cells contained
within while reducing the amount of medium that would be consumed
by the process relative to a process where the medium was being
perfused straight through without recycling.
[0135] The rate of recycle can be modulated on the basis of
required gas exchange and nutrient supply. For example, in a cell
culture process where T cells are expanded from a small number to a
much larger number, the initial stage of the culture can be carried
out at low flow rate perfusion with 100% recycle. This is because
the nutrients in the closed perfusion loop are adequate for the
small number of cells and the flow rate is set to be sufficient to
ensure enough gas exchange (oxygen in, CO2 out). Then, as the cells
start to expand, their need for nutrients and gas exchange grows.
Growth is monitored and can form the basis of decisions associated
with increasing perfusion flow rate (to increase gas exchange) and
changing the extent of recycle (recycle only a portion of the
medium and add new medium in progressively increasing fractions).
In principle, this could be done dynamically and automatically.
[0136] In embodiments, the cell culture chamber includes one or
more sensors operably coupled to the cell culture chamber. The
system can be configured with various sensor configurations to
monitor different parameters and integrate with the control system.
The sensors may be capable of measuring one or more parameters
within the cell culture chamber, such as pH, dissolved oxygen,
total biomass, cell diameter, glucose concentration, lactate
concentration, and cell metabolite concentration. The system can be
customized with off-the-shelf single use sensors for glucose and
lactate that sample the perfusion effluent fluid and transmit data.
In some embodiments, the cartridges are optically clear and can be
interfaced with sensing modalities such as optical density or
Raman. In some embodiments the sensors may be operably coupled to a
waste line or a waste reservoir, and are configured to measure one
or more parameters of the fluid that flows therein. In certain
aspects, the one or more sensors are operably coupled to a computer
system having a central processing unit for carrying out
instructions, such that automatic monitoring and adjustment of
parameters is possible. The system may be configured to
automatically redirect a fluid back into a chamber via an inlet if
the fluid meets a certain parameter. In some embodiments,
instrumentation interfaces with a control system architecture using
computers, networks, and graphical user interfaces for process
management and other peripheral devices to interface with process
plant machinery. The waste tube may have a valve that can direct
the fluid to one location or another depending on whether the fluid
has a sufficient level of nutrients, for example. Additional
details regarding computer systems for implementing methods of the
present invention using the cell culture chambers is provided
below.
[0137] Systems Architecture
[0138] Aspects of the present disclosure described herein, such as
control of the movement of fluid through the system, as described
above, and the monitoring and controlling of various parameters,
can be performed using any type of computing device, such as a
computer or programmable logic controller (PLC), that includes a
processor, e.g., a central processing unit, or any combination of
computing devices where each device performs at least part of the
process or method. In some embodiments, systems and methods
described herein may be performed with a handheld device, e.g., a
smart tablet, a smart phone, or a specialty device produced for the
system.
[0139] Methods of the present disclosure can be performed using
software, hardware, firmware, hardwiring, or combinations of any of
these. Features implementing functions can also be physically
located at various positions, including being distributed such that
portions of functions are implemented at different physical
locations (e.g., imaging apparatus in one room and host workstation
in another, or in separate buildings, for example, with wireless or
wired connections).
[0140] Processors suitable for the execution of computer program
include, by way of example, both general and special purpose
microprocessors, and any one or more processor of any kind of
digital computer. Generally, a processor will receive instructions
and data from a read-only memory or a random access memory or both.
Elements of computer are a processor for executing instructions and
one or more memory devices for storing instructions and data.
Generally, a computer will also include, or be operatively coupled
to receive data from or transfer data to, or both, one or more
non-transitory mass storage devices for storing data, e.g.,
magnetic, magneto-optical disks, or optical disks. Information
carriers suitable for embodying computer program instructions and
data include all forms of non-volatile memory, including by way of
example semiconductor memory devices, (e.g., EPROM, EEPROM, solid
state drive (SSD), and flash memory devices); magnetic disks,
(e.g., internal hard disks or removable disks); magneto-optical
disks; and optical disks (e.g., CD and DVD disks). The processor
and the memory can be supplemented by, or incorporated in, special
purpose logic circuitry.
[0141] To provide for interaction with a user, the subject matter
described herein can be implemented on a computer having an I/O
device, e.g., a CRT, LCD, LED, or projection device for displaying
information to the user and an input or output device such as a
keyboard and a pointing device, (e.g., a mouse or a trackball), by
which the user can provide input to the computer. Other kinds of
devices can be used to provide for interaction with a user as well.
For example, feedback provided to the user can be any form of
sensory feedback (e.g., visual feedback, auditory feedback, or
tactile feedback), and input from the user can be received in any
form, including acoustic, speech, or tactile input.
[0142] The subject matter described herein can be implemented in a
computing system that includes a back-end component (e.g., a data
server), a middleware component (e.g., an application server), or a
front-end component (e.g., a client computer having a graphical
user interface or a web browser through which a user can interact
with an implementation of the subject matter described herein), or
any combination of such back-end, middleware, and front-end
components. The components of the system can be interconnected
through network by any form or medium of digital data
communication, e.g., a communication network. Examples of
communication networks include cell network (e.g., 3G or 4G), a
local area network (LAN), and a wide area network (WAN), e.g., the
Internet.
[0143] The subject matter described herein can be implemented as
one or more computer program products, such as one or more computer
programs tangibly embodied in an information carrier (e.g., in a
non-transitory computer-readable medium) for execution by, or to
control the operation of, data processing apparatus (e.g., a
programmable processor, a computer, or multiple computers). A
computer program (also known as a program, software, software
application, app, macro, or code) can be written in any form of
programming language, including compiled or interpreted languages
(e.g., C, C++, Perl), and it can be deployed in any form, including
as a stand-alone program or as a module, component, subroutine, or
other unit suitable for use in a computing environment. Systems and
methods of the invention can include instructions written in any
suitable programming language known in the art, including, without
limitation, C, C++, Perl, Java, ActiveX, HTML5, Visual Basic, or
JavaScript.
[0144] A computer program does not necessarily correspond to a
file. A program can be stored in a file or a portion of file that
holds other programs or data, in a single file dedicated to the
program in question, or in multiple coordinated files (e.g., files
that store one or more modules, sub-programs, or portions of code).
A computer program can be deployed to be executed on one computer
or on multiple computers at one site or distributed across multiple
sites and interconnected by a communication network.
[0145] A file can be a digital file, for example, stored on a hard
drive, SSD, CD, or other tangible, non-transitory medium. A file
can be sent from one device to another over a network (e.g., as
packets being sent from a server to a client, for example, through
a Network Interface Card, modem, wireless card, or similar).
[0146] Writing a file according to embodiments of the invention
involves transforming a tangible, non-transitory, computer-readable
medium, for example, by adding, removing, or rearranging particles
(e.g., with a net charge or dipole moment into patterns of
magnetization by read/write heads), the patterns then representing
new collocations of information about objective physical phenomena
desired by, and useful to, the user. In some embodiments, writing
involves a physical transformation of material in tangible,
non-transitory computer readable media (e.g., with certain optical
properties so that optical read/write devices can then read the new
and useful collocation of information, e.g., burning a CD-ROM). In
some embodiments, writing a file includes transforming a physical
flash memory apparatus such as NAND flash memory device and storing
information by transforming physical elements in an array of memory
cells made from floating-gate transistors. Methods of writing a
file are well-known in the art and, for example, can be invoked
manually or automatically by a program or by a save command from
software or a write command from a programming language.
[0147] Suitable computing devices typically include mass memory, at
least one graphical user interface, at least one display device,
and typically include communication between devices. The mass
memory illustrates a type of computer-readable media, namely
computer storage media. Computer storage media may include
volatile, nonvolatile, removable, and non-removable media
implemented in any method or technology for storage of information,
such as computer readable instructions, data structures, program
modules, or other data. Examples of computer storage media include
RAM, ROM, EEPROM, flash memory, or other memory technology, CD-ROM,
digital versatile disks (DVD) or other optical storage, magnetic
cassettes, magnetic tape, magnetic disk storage or other magnetic
storage devices, Radiofrequency Identification tags or chips, or
any other medium which can be used to store the desired information
and which can be accessed by a computing device.
[0148] As one skilled in the art would recognize as necessary or
best-suited for performance of the methods of the invention, a
computer system or machines employed in embodiments of the
invention may include one or more processors (e.g., a central
processing unit (CPU) a graphics processing unit (GPU) or both), a
main memory and a static memory, which communicate with each other
via a bus.
[0149] In an example embodiment shown in FIG. 12, system 600 can
include a computer 649 (e.g., laptop, desktop, or tablet). The
computer 649 may be configured to communicate across a network 609.
Computer 649 includes one or more processor 659 and memory 663 as
well as an input/output mechanism 654. Where methods of the
invention employ a client/server architecture, operations of
methods of the invention may be performed using server 613, which
includes one or more of processor 621 and memory 629, capable of
obtaining data, instructions, etc., or providing results via
interface module 625 or providing results as a file 617. Server 613
may be engaged over network 609 through computer 649 or terminal
667, or server 613 may be directly connected to terminal 667,
including one or more processor 675 and memory 679, as well as
input/output mechanism 671.
[0150] System 600 or machines according to example embodiments of
the invention may further include, for any of I/O 649, 637, or 671
a video display unit (e.g., a liquid crystal display (LCD) or a
cathode ray tube (CRT)). Computer systems or machines according to
some embodiments can also include an alphanumeric input device
(e.g., a keyboard), a cursor control device (e.g., a mouse), a disk
drive unit, a signal generation device (e.g., a speaker), a
touchscreen, an accelerometer, a microphone, a cellular radio
frequency antenna, and a network interface device, which can be,
for example, a network interface card (NIC), Wi-Fi card, or
cellular modem.
[0151] Memory 663, 679, or 629 according to example embodiments of
the invention can include a machine-readable medium on which is
stored one or more sets of instructions (e.g., software) embodying
any one or more of the methodologies or functions described herein.
The software may also reside, completely or at least partially,
within the main memory and/or within the processor during execution
thereof by the computer system, the main memory and the processor
also constituting machine-readable media. The software may further
be transmitted or received over a network via the network interface
device.
INCORPORATION BY REFERENCE
[0152] References and citations to other documents, such as
patents, patent applications, patent publications, journals, books,
papers, web contents, have been made throughout this disclosure.
All such documents are hereby incorporated herein by reference in
their entirety for all purposes.
EQUIVALENTS
[0153] While the present invention has been described in
conjunction with certain embodiments, one of ordinary skill, after
reading the foregoing specification, will be able to effect various
changes, substitutions of equivalents, and other alterations to the
compositions and methods set forth herein.
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